House Made Chipotle Sausage Sandwich Recipe

Prepare casings (if using)

Soak natural hog casings in warm water for 30 minutes, then flush both inside and out under running water. Keep refrigerated until ready to stuff.

Mix spices and aromatics

In a small bowl combine chopped chipotle peppers, adobo sauce, smoked paprika, ground cumin, garlic powder, onion powder, brown sugar, black pepper, and kosher salt. Stir to make a paste.

Combine meat and seasonings

Cut the cold ground pork (and smoked leftover pork, if using) into 1-inch chunks and place in a large metal bowl. Sprinkle the spice paste over the meat. Add the dry white wine (or water) and the 1/4 cup of ice. Using your hands, gently but thoroughly mix until the seasonings are evenly distributed and the mixture becomes tacky (about 2–3 minutes). Do not overwork — you want a good bind but not a dense texture.

Chill and test

Cover the bowl and refrigerate for 30–60 minutes to let flavors meld. To test seasoning, take a 1-inch patty and pan-fry in a skillet over medium-high heat until cooked through. Taste and adjust salt, sugar, or chipotle heat in the remaining mixture as needed.

Form sausages (links or patties)

For links: If stuffing, fit your sausage stuffer with a medium nozzle and thread a prepared casing on. Fill the hopper, keeping meat cold, and gently stuff to make 6 roughly 4–5 oz sausages, twisting into links and pricking any large air pockets with a pin. For patties: divide the mixture into six 4–5 oz portions and form gently into 1/2–3/4-inch thick patties.

Cook sausages

For links: poach gently in simmering water (not boiling) at 170–180°F (77–82°C) for 10–12 minutes until internal temp reaches 155°F (68°C). Finish by searing in a hot skillet with 1 tbsp oil for 1–2 minutes per side to brown. For patties: cook in a hot skillet with 1 tbsp oil over medium-high heat for 4–5 minutes per side until internal temp 155°F (68°C), pressing slightly to get good contact and browning.

While sausages chill, place sliced red onion in a heatproof jar. In a small saucepan bring apple cider vinegar, water, sugar and salt to a simmer until sugar dissolves. Pour the hot brine over the onions, press down so onions are submerged, cool to room temperature, then refrigerate at least 30 minutes (best 2 hours).

Prepare chipotle mayo

In a bowl combine mayonnaise, 1–2 teaspoons of finely chopped leftover chipotle peppers (from the sausage mix) or 1 tsp adobo sauce, and 1 tablespoon lime juice. Stir until smooth and taste; adjust for heat and acidity. This yields a smoky chipotle mayo to spread on buns.

Toast buns

Heat a skillet or griddle over medium heat. Butter the cut sides of Martin potato buns lightly (about 1/2 tsp per cut side). Toast buttered sides in the skillet until golden brown, about 1–2 minutes.

Assemble sandwiches

Spread chipotle mayo on both toasted bun halves. Place leaf lettuce or arugula on the bottom bun, top with the cooked chipotle sausage link or patty, add a tablespoon of pickled red onions (if using) and optional pickles, then crown with the top bun. Serve immediately.

Serving and storage

Serve hot. Leftover cooked sausages keep refrigerated in an airtight container for up to 3 days and can be reheated in a skillet or oven. Pickled onions keep up to 2 weeks refrigerated.